Tunable cell structure and mechanism in porous thermoplastic polyurethane micro-film fabricated by a diffusion-restricted physical foaming process

Surface Modification of Polyimide Aerogel by Thermoplastic Polyurethane for Enhanced Mechanical Strength and Thermal Insulation Performance

Polyimide (PI) aerogel is a good thermal insulation material with the highest temperature resistance in practical application. But the mechanical strength of PI aerogels prepared by freeze-drying or thermoimide methods is weak. In this research, TPU was selected as an aging solution to solve the problem of the low mechanical strength of PI aerogel prepared by the freeze-drying method. Previous work has certified that the coupling of PI and thermoplastic polyurethane (TPU) can enhance the mechanical strength of PI aerogel to a certain extent due to the flexibility of TPU. But excessive TPU will change the PI structure in the cross-linking process and decrease the mechanical strength of the aerogel. Thus, a new kind of PI gel modification method was provided by using TPU as an aging solution, and the mechanical strength of PI aerogel is improved to 3.06 MPa. Furthermore, the shrinkage, specific surface area, waterproof angle, and thermal conductivity all show good performance, thus enabling PI aerogel to be used in many aspects. Specially, the method is simple and can be used to prepare some other high-strength aerogels.

Skinless Polyphenylene Sulfide Foam with Enhanced Thermal Insulation Properties Fabricated by Constructing Aligned Gas Barrier Layers for Surface-Constrained sc-CO2 Foaming

A solid skin layer inevitably forms on the foam surface for supercritical carbon dioxide (sc-CO₂) foaming technology, leading to deterioration of some inherent properties of polymeric foams. In this work, skinless polyphenylene sulfide (PPS) foam was fabricated with a surface-constrained sc-CO₂ foaming method by innovatively constructing aligned epoxy resin/ferromagnetic graphene oxide composites (EP/GO@Fe₃O₄) as a CO₂ barrier layer under a magnetic field. Introduction of GO@Fe₃O₄ and its ordered alignment led to an obvious decrease in the CO₂ permeability coefficient of the barrier layer, a significant increase of the CO₂ concentration in the PPS matrix, and a decrease of desorption diffusivity in the depressurization stage, suggesting that the composite layers effectively inhibited the escape of CO₂ dissolved in the matrix. Meanwhile, the strong interfacial interaction between the composite layer and the PPS matrix remarkably enhanced the heterogeneous nucleation of cells at the interface, resulting in elimination of the solid skin layer and formation of an obvious cellular structure on the foam surface. Moreover, by the alignment of GO@Fe₃O₄ in EP, the CO₂ permeability coefficient of the barrier layer became much lower, and the cell density on the foam surface further increased with decreasing cell size, which was even higher than that of the cross section of foam, attributed to stronger heterogeneous nucleation at the interface than the homogeneous nucleation in the core region of the sample. As a result, the thermal conductivity of the skinless PPS foam reached as low as 0.0365 W/m·k, decreasing by 49.5% compared with that of regular PPS foam, showing a remarkable improvement in the thermal insulation properties of PPS foam. This work provided a novel and effective method for fabricating skinless PPS foam with enhanced thermal insulation properties.

Green and effective fabrication of porous surfaces with adjustable cell structure by foaming at incomplete healed polymer-polymer interface

Porous surfaces of materials have shown huge potentialities for endowing materials with multifarious functions. Despite introducing gas-confined-barriers in supercritical CO₂ foaming technology is effective to weaken the gas escape effect and facilitate the preparation of porous surfaces, the differences in intrinsic properties between barriers and polymers result in bottlenecks like cell structure adjustment limitation and incompletely eliminated solid skin layers. This study undertakes a preparation approach for porous surfaces by foaming at incompletely healed polystyrene/polystyrene interfaces. In contrast with employing gas-confined-barriers reported before, the porous surfaces foamed at incompletely healed polymer/polymer interfaces show a monolayer, full-open cell morphology, and wide adjustable range in cell structures including cell size (120 nm∼15.68 μm), cell density (3.40 × 10⁵ cells/cm²∼3.47 × 10⁹ cells/cm²), and surface roughness (0.50 μm∼7.22 μm). Furthermore, the wettability of obtained porous surfaces depending on the cell structures is systematically discussed. Finally, a super-hydrophobic surface with hierarchical micro-nanoscale roughness, low water adhesion, and high water-impact resistance is built by depositing nanoparticles on a porous surface. Consequently, this study offers a clean and simple method to prepare porous surfaces with adjustable cell structures, which is expected to open a door to developing a new fabrication technique for micro/nano-porous surfaces.

Supercritical Fluid Microcellular Foaming of High-Hardness TPU via a Pressure-Quenching Process: Restricted Foam Expansion Controlled by Matrix Modulus and Thermal Degradation

High-hardness thermoplastic polyurethane (HD-TPU) presents a high matrix modulus, low-temperature durability, and remarkable abrasion resistance, and has been used in many advanced applications. However, the fabrication of microcellular HD-TPU foam is rarely reported in the literature. In this study, the foaming behavior of HD-TPU with a hardness of 75D was investigated via a pressure-quenching foaming process using CO₂ as a blowing agent. Microcellular HD-TPU foam with a maximum expansion ratio of 3.9-fold, a cell size of 25.9 μm, and cell density of 7.8 × 10⁸ cells/cm³ was prepared, where a high optimum foaming temperature of about 170 °C had to be applied with the aim of softening the polymer's matrix modulus. However, the foaming behavior of HD-TPU deteriorated when the foaming temperature further increased to 180 °C, characterized by the presence of coalesced cells, microcracks, and a high foam density of 1.0 g/cm³ even though the crystal domains still existed within the matrix. The cell morphology evolution of HD-TPU foam was investigated by adjusting the saturation time, and an obvious degradation occurred during the high-temperature saturation process. A cell growth mechanism of HD-TPU foams in degradation environments was proposed to explain this phenomenon based on the gas escape through the defective matrix.

A lightweight polyurethane-carbon microsphere composite foam for electromagnetic shielding

In this study, we have produced a lightweight foam composite material by a simple freeze-drying method, which is composed of carboxylated multi-walled carbon nanotubes (MWCNTs), mesoporous carbon hollow microspheres (MCHMs), water-based polyurethane (WPU), and polyvinyl alcohol (PVA). MCHMs were prepared by a novel and facile method. We found that the electromagnetic shielding performance of foam composites can be adjusted by adjusting the density of foam composites, and the electromagnetic shielding performance of composites can be enhanced through the synergistic effect of hollow mesoporous carbon and MWCNTs. The composite material with a density of 232.8042 mg·cm−3 and 40 wt% MWCNT has a δ of 30.2 S·m−1 and SE of 23 dB. After adding 10 wt% MCHMs to the composite material, δ reaches 33.2 S·m−1, and SE reaches 28 dB. Both absorption losses accounted for 70%. The increase in the content of MWCNT, the increase in density, and the introduction of MCHMs all have a positive effect on the δ and SE of the composite material.

Robust and Multifunctional Porous Polyetheretherketone Fiber Fabricated via a Microextrusion CO2 Foaming

Fabrication of multifunctional porous fibers with excellent mechanical properties has attracted abundant attention in the fields of personal thermal management textiles and smart wearable devices. However, the high cost and harsh preparation environment of the traditional solution-solvent phase separation method for making porous fibers aggravates the problems of resource consumption and environmental pollution. Herein, a microextrusion process that combines environmentally friendly CO₂ physical foaming with fused deposition modeling technology is proposed, via the dual features of high gas uptake and restricted cell growth, to implement the continuous production of porous polyetheretherketone (PEEK) fibers with a production efficiency of 10.5 cm s^-1 . The porous PEEK fiber exhibits excellent stretchability (234.8% strain) and good high-temperature thermal insulation property. The open-cell structure on the surface is favorable for the adsorption to achieve superhydrophobicity (154.4°) and high-efficiency photocatalytic degradation of rhodamine B (90.4%). Moreover, the parameterized controllability of the cell structure is beneficial to widening the multifunctional window. In short, the first porous PEEK physical foaming fiber, which opens up a new avenue for the application expansion, especially in the medical field, is realized.

A green fabrication method of poly (lactic acid) perforated membrane via tuned crystallization and gas diffusion process

Poly (lactic acid) (PLA) perforated membrane is typically obtained through the solvent-volatilization-induced or non-solvent-induced phase separation (NIPS) method. However, the residual organic solvents would unavoidably limit the application of PLA perforated membrane in biomedical and high-end water purification fields. Herein, an innovative solution-free method was proposed for preparing the PLA perforated membrane via a simple and environmentally friendly way. We have successfully fabricated the PLA perforated membrane using a physical foaming technique with CO₂ as the blowing agent. By tuning the primary film thickness, saturation pressure, and foaming temperature, PLA perforated membrane's cell morphology could be accordingly adjusted. The PLA perforated membrane with a highly-ordered straight pore channel and high open cell content (OCC) approximately 72% was obtained under a mild condition. The formation mechanism of the PLA perforated membrane was discussed via the interaction of crystallization behavior and gas diffusion process. This green and solvent-free PLA perforated membrane possesses great potential for use in areas like the tissue engineering and high-end water purification.